Battery test module

ABSTRACT

A storage battery includes a battery housing and a plurality of electrochemical cells in the battery housing electrically connected to terminals of the battery. A battery test module is mounted to the battery housing and electrically coupled to the terminals through Kelvin connections. A display or other output is configured to output battery condition information from the battery test module. Battery post extensions couple the battery test module to terminals of the battery.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. provisional patentapplication Ser. No. 60/341,902, filed Dec. 19, 2001 and is aContinuation-In-Part of U.S. patent application Ser. No. 10/217,913,filed Aug. 13, 2002 which is a Continuation-In-Part of U.S. patentapplication Ser. No. 09/880,473, filed Jun. 13, 2001, now abandonedwhich is a Continuation-In-Part of and claims priority of U.S. patentapplication Ser. No. 09/780,146, filed Feb. 9, 2001, now abandoned whichis based on and claims the benefit of U.S. provisional patentapplication Ser. No. 60/181,854, filed Feb. 11, 2000; U.S. Provisionalpatent application Ser. No. 60/204,345, filed May 15, 2000; U.S.provisional patent application Ser. No. 60/218,878, filed Jul. 18, 2000;and U.S. provisional patent application Ser. No. 60/224,092, filed Aug.9, 2000, and is a Continuation-In-Part of and claims priority of U.S.patent application Ser. No. 09/544,696, filed Apr. 7, 2000, now U.S.Pat. No. 6,323,650, which claims the benefit of priority of U.S.provisional patent application Ser. No. 60/128,366, filed Apr. 8, 1999,the contents of which are hereby incorporated by reference in theirentirety.

BACKGROUND OF THE INVENTION

The present invention relates to storage batteries. More specifically,the present invention relates to storage batteries with integral batterytesters.

Storage batteries, such as lead acid storage batteries, are used in avariety of applications such as automotive vehicles and standby powersources. Typical storage batteries consist of a plurality of individualstorage cells which are electrically connected in series. Each cell canhave a voltage potential of about 2.1 volts, for example. By connectingthe cells in the series, the voltages of the individual cells are addedin a cumulative manner. For example, in a typical automotive storagebattery, six storage cells are used to provide a total voltage of about12.6 volts. The individual cells are held in a housing and the entireassembly is commonly referred to as the “battery.”

It is frequently desirable to ascertain the condition of a storagebattery. Various testing techniques have been developed over the longhistory of storage batteries. For example, one technique involves theuse of a hygrometer in which the specific gravity of the acid mixture inthe battery is measured. Electrical testing has also been used toprovide less invasive battery testing techniques. A very simpleelectrical test is to simply measure the voltage across the battery. Ifthe voltage is below a certain threshold, the battery is determined tobe bad. Another technique for testing a battery is referred to as a loadtest. In a load test, the battery is discharged using a known load. Asthe battery is discharged, the voltage across the battery is monitoredand used to determine the condition of the battery. More recently, atechnique has been pioneered by Dr. Keith S. Champlin and Midtronics,Inc. of Willowbrook, Ill. for testing storage battery by measuring adynamic parameter of the battery such as the dynamic conductance of thebattery. This technique is described in a number of United StatesPatents and United States Patent Applications, for example, U.S. Pat.No. 3,873,911, issued Mar. 25, 1975, to Champlin, entitled ELECTRONICBATTERY TESTING DEVICE; U.S. Pat. No. 3,909,708, issued Sep. 30, 1975,to Champlin, entitled ELECTRONIC BATTERY TESTING DEVICE; U.S. Pat. No.4,816,768, issued Mar. 28, 1989, to Champlin, entitled ELECTRONICBATTERY TESTING DEVICE; U.S. Pat. No. 4,825,170, issued Apr. 25, 1989,to Champlin, entitled ELECTRONIC BATTERY TESTING DEVICE WITH AUTOMATICVOLTAGE SCALING; U.S. Pat. No. 4,881,038, issued Nov. 14, 1989, toChamplin, entitled ELECTRONIC BATTERY TESTING DEVICE WITH AUTOMATICVOLTAGE SCALING TO DETERMINE DYNAMIC CONDUCTANCE; U.S. Pat. No.4,912,416, issued Mar. 27, 1990, to Champlin, entitled ELECTRONICBATTERY TESTING DEVICE WITH STATE-OF-CHARGE COMPENSATION; U.S. Pat. No.5,140,269, issued Aug. 18, 1992, to Champlin, entitled ELECTRONIC TESTERFOR ASSESSING BATTERY/CELL CAPACITY; U.S. Pat. No. 5,343,380, issuedAug. 30, 1994, entitled METHOD AND APPARATUS FOR SUPPRESSING TIMEVARYING SIGNALS IN BATTERIES UNDERGOING CHARGING OR DISCHARGING; U.S.Pat. No. 5,572,136, issued Nov. 5, 1996, entitled ELECTRONIC BATTERYTESTER WITH AUTOMATIC COMPENSATION FOR LOW STATE-OF-CHARGE; U.S. Pat.No. 5,574,355, issued Nov. 12, 1996, entitled METHOD AND APPARATUS FORDETECTION AND CONTROL OF THERMAL RUNAWAY IN A BATTERY UNDER CHARGE; U.S.Pat. No. 5,585,416, issued Dec. 10, 1996, entitled APPARATUS AND METHODFOR STEP-CHARGING BATTERIES TO OPTIMIZE CHARGE ACCEPTANCE; U.S. Pat. No.5,585,728, issued Dec. 17, 1996, entitled ELECTRONIC BATTERY TESTER WITHAUTOMATIC COMPENSATION FOR LOW STATE-OF-CHARGE; U.S. Pat. No. 5,589,757,issued Dec. 31, 1996, entitled APPARATUS AND METHOD FOR STEP-CHARGINGBATTERIES TO OPTIMIZE CHARGE ACCEPTANCE; U.S. Pat. No. 5,592,093, issuedJan. 7, 1997, entitled ELECTRONIC BATTERY TESTING DEVICE LOOSE TERMINALCONNECTION DETECTION VIA A COMPARISON CIRCUIT; U.S. Pat. No. 5,598,098,issued Jan. 28, 1997, entitled ELECTRONIC BATTERY TESTER WITH VERY HIGHNOISE IMMUNITY; U.S. Pat. No. 5,656,920, issued Aug. 12, 1997, entitledMETHOD FOR OPTIMIZING THE CHARGING LEAD-ACID BATTERIES AND ANINTERACTIVE CHARGER; U.S. Pat. No. 5,757,192, issued May 26, 1998,entitled METHOD AND APPARATUS FOR DETECTING A BAD CELL IN A STORAGEBATTERY; U.S. Pat. No. 5,821,756, issued Oct. 13, 1998, entitledELECTRONIC BATTERY TESTER WITH TAILORED COMPENSATION FOR LOWSTATE-OF-CHARGE; U.S. Pat. No. 5,831,435, issued Nov. 3, 1998, entitledBATTERY TESTER FOR JIS STANDARD; U.S. Pat. No. 5,914,605, issued Jun.22, 1999, entitled ELECTRONIC BATTERY TESTER; U.S. Pat. No. 5,945,829,issued Aug. 31, 1999, entitled MIDPOINT BATTERY MONITORING; U.S. Pat.No. 6,002,238, issued Dec. 14, 1999, entitled METHOD AND APPARATUS FORMEASURING COMPLEX IMPEDANCE OF CELLS AND BATTERIES; U.S. Pat. No.6,037,751, issued Mar. 14, 2000, entitled APPARATUS FOR CHARGINGBATTERIES; U.S. Pat. No. 6,037,777, issued Mar. 14, 2000, entitledMETHOD AND APPARATUS FOR DETERMINING BATTERY PROPERTIES FROM COMPLEXIMPEDANCE/ADMITTANCE; U.S. Pat. No. 6,051,976, issued Apr. 18, 2000,entitled METHOD AND APPARATUS FOR AUDITING A BATTERY TEST; U.S. Pat. No.6,081,098, issued Jun. 27, 2000, entitled METHOD AND APPARATUS FORCHARGING A BATTERY; U.S. Pat. No. 6,091,245, issued Jul. 18, 2000,entitled METHOD AND APPARATUS FOR AUDITING A BATTERY TEST; U.S. Pat. No.6,104,167, issued Aug. 15, 2000, entitled METHOD AND APPARATUS FORCHARGING A BATTERY; U.S. Pat. No. 6,137,269, issued Oct. 24, 2000,entitled METHOD AND APPARATUS FOR ELECTRONICALLY EVALUATING THE INTERNALTEMPERATURE OF AN ELECTROCHEMICAL CELL OR BATTERY; U.S. Pat. No.6,163,156, issued Dec. 19, 2000, entitled ELECTRICAL CONNECTION FORELECTRONIC BATTERY TESTER; U.S. Pat. No. 6,172,483, issued Jan. 9, 2001,entitled METHOD AND APPARATUS FOR MEASURING COMPLEX IMPEDANCE OF CELLAND BATTERIES; U.S. Pat. No. 6,172,505, issued Jan. 9, 2001, entitledELECTRONIC BATTERY TESTER; U.S. Pat. No. 6,222,369, issued Apr. 24,2001, entitled METHOD AND APPARATUS FOR DETERMINING BATTERY PROPERTIESFROM COMPLEX IMPEDANCE/ADMITTANCE; U.S. Pat. No. 6,225,808, issued May1, 2001, entitled TEST COUNTER FOR ELECTRONIC BATTERY TESTER; U.S. Pat.No. 6,249,124, issued Jun. 19, 2001, entitled ELECTRONIC BATTERY TESTERWITH INTERNAL BATTERY; U.S. Pat. No. 6,259,254, issued Jul. 10, 2001,entitled APPARATUS AND METHOD FOR CARRYING OUT DIAGNOSTIC TESTS ONBATTERIES AND FOR RAPIDLY CHARGING BATTERIES; U.S. Pat. No. 6,262,563,issued Jul. 17, 2001, entitled METHOD AND APPARATUS FOR MEASURINGCOMPLEX ADMITTANCE OF CELLS AND BATTERIES; U.S. Pat. No. 6,294,896,issued Sep. 25, 2001; entitled METHOD AND APPARATUS FOR MEASURINGCOMPLEX SELF-IMMITANCE OF A GENERAL ELECTRICAL ELEMENT; U.S. Pat. No.6,294,897, issued Sep. 25, 2001, entitled METHOD AND APPARATUS FORELECTRONICALLY EVALUATING THE INTERNAL TEMPERATURE OF AN ELECTROCHEMICALCELL OR BATTERY; U.S. Pat. No. 6,304,087, issued Oct. 16, 2001, entitledAPPARATUS FOR CALIBRATING ELECTRONIC BATTERY TESTER; U.S. Pat. No.6,310,481, issued Oct. 30, 2001, entitled ELECTRONIC BATTERY TESTER;U.S. Pat. No. 6,313,607, issued Nov. 6, 2001, entitled METHOD ANDAPPARATUS FOR EVALUATING STORED CHARGE IN AN ELECTROCHEMICAL CELL ORBATTERY; U.S. Pat. No. 6,313,608, issued Nov. 6, 2001, entitled METHODAND APPARATUS FOR CHARGING A BATTERY; U.S. Pat. No. 6,316,914, issuedNov. 13, 2001, entitled TESTING PARALLEL STRINGS OF STORAGE BATTERIES;U.S. Pat. No. 6,323,650, issued Nov. 27, 2001, entitled ELECTRONICBATTERY TESTER; U.S. Pat. No. 6,329,793, issued Dec. 11, 2001, entitledMETHOD AND APPARATUS FOR CHARGING A BATTERY; U.S. Pat. No. 6,331,762,issued Dec. 18, 2001, entitled ENERGY MANAGEMENT SYSTEM FOR AUTOMOTIVEVEHICLE; U.S. Pat. No. 6,332,113, issued Dec. 18, 2001, entitledELECTRONIC BATTERY TESTER; U.S. Pat. No. 6,351,102, issued Feb. 26,2002, entitled AUTOMOTIVE BATTERY CHARGING SYSTEM TESTER; U.S. Pat. No.6,359,441, issued Mar. 19, 2002, entitled ELECTRONIC BATTERY TESTER;U.S. Pat. No. 6,363,303, issued Mar. 26, 2002, entitled ALTERNATORDIAGNOSTIC SYSTEM, U.S. Ser. No. 09/595,102, filed Jun. 15, 2000,entitled APPARATUS AND METHOD FOR TESTING RECHARGEABLE ENERGY STORAGEBATTERIES; U.S. Ser. No. 09/703,270, filed Oct. 31, 2000, entitledELECTRONIC BATTERY TESTER; U.S. Ser. No. 09/575,629, filed May 22, 2000,entitled VEHICLE ELECTRICAL SYSTEM TESTER WITH ENCODED OUTPUT; U.S. Ser.No. 09/780,146, filed Feb. 9, 2001, entitled STORAGE BATTERY WITHINTEGRAL BATTERY TESTER; U.S. Ser. No. 09/816,768, filed Mar. 23, 2001,entitled MODULAR BATTERY TESTER; U.S. Ser. No. 09/756,638, filed Jan. 8,2001, entitled METHOD AND APPARATUS FOR DETERMINING BATTERY PROPERTIESFROM COMPLEX IMPEDANCE/ADMITTANCE; U.S. Ser. No. 09/862,783, filed May21, 2001, entitled METHOD AND APPARATUS FOR TESTING CELLS AND BATTERIESEMBEDDED IN SERIES/PARALLEL SYSTEMS; U.S. Ser. No. 09/483,623, filedJan. 13, 2000, entitled ALTERNATOR TESTER; U.S. Ser. No. 09/870,410,filed May 30, 2001, entitled INTEGRATED CONDUCTANCE AND LOAD TEST BASEDELECTRONIC BATTERY TESTER; U.S. Ser. No. 09/960,117, filed Sep. 20,2001, entitled IN-VEHICLE BATTERY MONITOR; U.S. Ser. No. 09/908,389,filed Jul. 18, 2001, entitled BATTERY CLAMP WITH INTEGRATED CIRCUITSENSOR; U.S. Ser. No. 09/908,278, filed Jul. 18, 2001, entitled BATTERYCLAMP WITH EMBEDDED ENVIRONMENT SENSOR; U.S. Ser. No. 09/880,473, filedJun. 13, 2001; entitled BATTERY TEST MODULE; U.S. Ser. No. 09/876,564,filed Jun. 7, 2001, entitled ELECTRONIC BATTERY TESTER; U.S. Ser. No.09/878,625, filed Jun. 11, 2001, entitled SUPPRESSING INTERFERENCE IN ACMEASUREMENTS OF CELLS, BATTERIES AND OTHER ELECTRICAL ELEMENTS; U.S.Ser. No. 09/902,492, filed Jul. 10, 2001, entitled APPARATUS AND METHODFOR CARRYING OUT DIAGNOSTIC TESTS ON BATTERIES AND FOR RAPIDLY CHARGINGBATTERIES; and U.S. Ser. No. 09/940,684, filed Aug. 27, 2001, entitledMETHOD AND APPARATUS FOR EVALUATING STORED CHARGE IN AN ELECTROCHEMICALCELL OR BATTERY; U.S. Ser. No. 09/977,049, filed Oct. 12, 2001, entitledPROGRAMMABLE CURRENT EXCITER FOR MEASURING AC IMMITTANCE OF CELLS ANDBATTERIES; U.S. Ser. No. 10/047,923, filed Oct. 23, 2001, entitledAUTOMOTIVE BATTERY CHARGING SYSTEM TESTER, U.S. Ser. No. 10/046,659,filed Oct. 29, 2001, entitled ENERGY MANAGEMENT SYSTEM FOR AUTOMOTIVEVEHICLE; U.S. Ser. No. 09/993,468, filed Nov. 14, 2001, entitled KELVINCONNECTOR FOR A BATTERY POST; U.S. Ser. No. 09/992,350, filed Nov. 26,2001, entitled ELECTRONIC BATTERY TESTER, U.S. Ser. No. 10/042,451,filed Jan. 8, 2002, entitled BATTERY CHARGE CONTROL DEVICE; U.S. Ser.No. 10/042,451, filed Jan. 8, 2002, entitled BATTERY CHARGE CONTROLDEVICE, U.S. Ser. No. 10/073,378, filed Feb. 8, 2002, entitled METHODAND APPARATUS USING A CIRCUIT MODEL TO EVALUATE CELL/BATTERY PARAMETERS;U.S. Ser. No. 10/093,853, filed Mar. 7, 2002, entitled ELECTRONICBATTERY TESTER WITH NETWORK COMMUNICATION; U.S. Ser. No. 60/364,656,filed Mar. 14, 2002, entitled ELECTRONIC BATTERY TESTER WITH LOWTEMPERATURE RATING DETERMINATION; U.S. Ser. No. 10/101,543, filed Mar.19, 2002, entitled ELECTRONIC BATTERY TESTER; U.S. Ser. No. 10/112,114,filed Mar. 28, 2002; U.S. Ser. No. 10/109,734, filed Mar. 28, 2002; U.S.Ser. No. 10/112,105, filed Mar. 28, 2002, entitled CHARGE CONTROL SYSTEMFOR A VEHICLE BATTERY; U.S. Ser. No. 10/112,998, filed Mar. 29, 2002,entitled BATTERY TESTER WITH BATTERY REPLACEMENT OUTPUT; which areincorporated herein in their entirety.

In general, battery testers have been separate pieces of equipment whichcan be moved between storage batteries and electrically coupled to astorage battery. The prior art has lacked a simple technique for thetesting of a storage battery without relying on separate testingequipment.

SUMMARY OF THE INVENTION

A storage battery includes a battery housing and a plurality ofelectrochemical cells in the battery housing electrically connected toterminals of the battery. A battery test module is mounted to thebattery housing and electrically coupled to the terminals through Kelvinconnections. A display or other output is configured to output batterycondition information from the battery test module. Another aspect ofthe invention includes battery post extensions that couple the batterytest module to terminals of the battery.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side plan view of a storage battery including a battery testmodule in accordance with the present invention.

FIGS. 2A and 2B are top plan views of the storage battery of FIG. 1.

FIG. 3 is a side cross-sectional view of the storage battery of FIGS. 1and 2 taken along the line labeled 3—3 in FIG. 2.

FIG. 4 is a block diagram of a storage battery in accordance with thepresent invention.

FIG. 5 is an electrical diagram of one example embodiment.

FIG. 6 is an electrical diagram of another example embodiment.

FIG. 7 is a block diagram of a storage battery in accordance withanother example embodiment of the present invention.

FIG. 8 is a block diagram illustrating various types of battery testcondition information provided by the battery test module.

FIG. 9 is a simplified block diagram of a storage battery with a batterytest module that can communicate with an external charger/tester inaccordance with an embodiment of the present invention.

FIG. 10 is a side plan view of the storage battery upon which thebattery test module is affixed.

FIG. 11 is a top plan view of the storage battery of FIG. 10.

FIG. 12 illustrates a cross section of a portion of the test module.

FIG. 13A illustrates a cross section of a portion of the battery.

FIG. 13B illustrates a battery post extension in accordance with anembodiment of the present invention.

FIGS. 14 and 15 are top plan views of storage battery showing differentembodiments of battery post extensions.

FIGS. 16-1 through 16-3 illustrate different embodiments of fastenersused to couple the battery test module to the battery.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In one aspect of the present invention a storage battery is providedhaving an integrated battery test module for performing a battery teston electrical cells of the storage battery. As used herein “integrated”can include a separate module which is attached to the battery housing.In one embodiment, the battery test module is electrically coupled tothe electrical cells of the storage battery through Kelvin connections.In certain aspects, Kelvin connections are not used. As the battery testmodule is integral with the battery, an operator can test the batterywithout relying on external battery test equipment. In one embodiment,the battery test is one that can be easily performed by an unskilledoperator. The battery test module is preferably manufactured using lowcost techniques which may be integrated with a storage battery withoutan excessive increase in the cost to produce the battery. Further, thebattery test module is capable of outputting battery conditioninformation to an output device that is attached to the battery housingand/or to a separate output that may be at a location that is remotefrom the storage battery. As used herein, battery condition informationcan be any information generated by the battery test module or anybattery test result obtained by the battery test module. Examples ofbattery condition information include real-time measurements (such as,battery voltage, current, temperature, etc.) conducted by the testmodule, intermediate test results and final test results obtained by thebattery test module.

FIG. 1 is a side plan view of a storage battery 10 in accordance withthe present invention. Storage battery 10 includes a positive terminal12 and a negative terminal 14. A battery test module 16 is mounted to ahousing 18 of the storage battery.

FIGS. 2A and 2B are top plan views of the storage battery 10 of FIG. 1.As illustrated in FIG. 2A, battery test module 16 includes an optionalinput 20 and optional outputs 22 and 24. Input 20 can be, for example, apush button or other input which can be actuated by an operator orautomated by a system. Output 22 can be, for example, an LED or othertype of visual indicator which provides a pass/fail indication of abattery test. However, in other aspects, output 24 can be used to senddata, using any appropriate technique, to a remote computer ormonitoring system. Output 24 can be used to provide a quantitativeoutput of a battery test. In FIG. 2B, the output 22 is in the form of aseries of outputs 23A, 23B, 23C and 23D which can comprise LEDs.

FIG. 3 is a side cross-sectional view of battery 10 taken along the linelabeled 3—3 in FIG. 2. As illustrated in FIG. 3, battery 10 is a storagebattery such as a lead-acid battery and includes a number ofelectrochemical cells which are electrically connected in series byconductors 32. This forms a string of cells 30 having one endelectrically coupled to positive terminal 12 through conductor 34 andhaving the other end electrically coupled to negative terminal 14through conductor 36. As illustrated in FIG. 3, battery test module 16is coupled to terminals 12 and 14 through two pairs of electricalconnections which provide Kelvin connections 38 and 40. The connectionsto terminals 12 and 14 can be achieved through direct contact with theexternal battery posts 12 or 14, through battery post extensions tooled,molded or configured to the battery posts 12 or 14, through directinternal or external wiring connections to battery posts 12 or 14, orthrough a reconfiguration of the battery casing and battery posts 12 or14.

In operation, a user can test the condition of battery 10 using batterytest module 16. For example, through actuation of button 20 or anotherinput device, a test can be performed on the battery. The results of thebattery test are displayed on outputs 22 or 24. In one embodiment,battery test module 16 monitors the battery and waits for a period whenthe battery is not in use or there is not excessive noise on theelectrical system to which the battery is connected and then performs atest on the battery. The results of the battery test can be stored inmemory and displayed on output 22 or 24. In such an embodiment, an inputsuch as input 20 is not required to activate the test. However, in suchan embodiment, the circuitry within test module 16 could cause thebattery to discharge over an extended period.

In the embodiment shown in FIG. 2B, battery test module 16 compares thevoltage between terminals 12 and 14 to a number of different thresholdvoltages. Depending upon the voltage of battery 10, an appropriatenumber of LEDs 23A–D are illuminated on test module 16. For example,each LED can correspond to a different threshold. These thresholds canbe spaced as desired. The LEDs 23A–D can also be of different colors.For example, 23A can be a read LED while 23D can be a green LED. In aslightly more complex embodiment, a load, such as a load resistance, inmodule 16 can be applied to battery 10 during or prior to a voltagemeasurement. The output of module 16 can be a function of the appliedload.

In one embodiment, test module 16 illuminates outputs 23A–Dconsecutively until the appropriate threshold is reached. To provide amore desirable user-interface, a small delay can be introduced betweenthe illumination of the each LED. The timing can be as appropriate. Theresults of the battery test can be maintained on outputs 23A–D for adesired length of time, preferably sufficiently long for a user toobserve the test result. In one embodiment, the appropriate number ofLEDs remain lit until the test is complete. In another embodiment, onlya single LED is lit at a time. Of course, any number of LEDs andthresholds may be used. In other embodiments, additional information canbe communicated to an operator by flashing LEDs providing a code or awarning.

The circuitry of the battery tester in the embodiment of FIG. 2B can beimplemented using simple comparators and timing circuits as will beapparent to those skilled in the art. A more complex embodiment caninclude a small microprocessor. Typically, the circuitry of battery testmodule 16 is powered by storage battery 10.

FIG. 4 shows a more detailed view of the electrical connections betweenbattery test module 16 and the cells 30 of the battery 10. Cells 30 areillustrated using the electrical symbol for a battery. Battery testmodule 16 is coupled to electrochemical cells 30 through Kelvinconnections 38 and 40.

A microprocessor in battery test module 16 can store information inmemory 44 for later retrieval. For example, information regarding thehistory of battery usage and battery charging can be maintained inmemory for later output. A special access code can be entered throughuser input 20 to cause the data to be output through output 22 or 24 orother output. In one embodiment, the output can be an audio output suchas a series of tones or pre-recorded words. The input can comprise aspecial series of buttons or timing of pressing of buttons. Alternativeinputs can also be provided such as an IR sensor, a vibration sensor, amagnetic switch, a proximity receiver which inductively couples to anexternal device or others. The output can be provided by energizing anLED in accordance with a digital code which could be read by an externaldevice. Other types of outputs can be provided through an IR link, aproximity communication technique such as inductive coupling, etc. Othertechniques include a serial or other hard wired output, RF and optical.Further, a battery test can be initiated based upon an input receivedthrough input 20 or 26, using any of the above communication techniques,from a remote computer or other circuitry. This can also be used toinitiate a data dump of information stored in memory. Inputs and outputscan also be provided to test module 16 by modulating data onto positiveand negative terminals 12 and 14. The data can be received ortransmitted using transmit and receive circuitry in battery module 16.Various modulation techniques are known in the art. In one embodiment,the modulation technique is selected such that it does not interferewith external circuitry to which battery 10 may be coupled.

The data recording and reporting technique allows a manufacturer tomonitor usage of a battery. For example, the manufacturer coulddetermine that the battery was left in an uncharged condition for anextended period, prior to sale, which caused damage to the battery. Thedata stored in memory can be keyed to date information if suchinformation is maintained by a microprocessor in battery test module 16such that various events in the life of the battery 18 can be linked tospecific dates. Examples of other information which can be stored inmemory 44 include the date of manufacture, battery ratings, batteryserial number of other identification, distribution chain, etc.

FIG. 4 also illustrates another aspect of the present invention. In FIG.4, element 10 can also illustrate a standby jumper or auxiliary system10 which contains an internal battery 30. Jumper cables or other outputsuch as a cigarette lighter adapter, can couple to battery 30 and can beused to provide auxiliary power to an automotive vehicle. For example,such a system can be used to provide a brief charge to a vehicle or tostart a vehicle having a dead battery. This can be used to “jump start”the vehicle. Such devices are known in the art and are typically small,portable devices which contain an internal battery. The internal batterycan be, for example, a gel cell, a NICAD battery, a nickel metal hydridebattery or other type of battery. One problem with such auxiliary powersystems is that the internal battery can fail without the knowledge ofthe user. When use of the of auxiliary power system is required, thebattery may have failed. Further, the type of a failure may be one whichis not easily detected in that the battery may provide a normal voltageoutput but is not capable of supplying a great deal of current for anyperiod of time. With the present invention, system 10 can also include atest module 16 for testing battery 30. In such an embodiment, a usercould periodically test battery 30 to ensure it has not failed. Further,test module 16 can periodically test battery 30 and provide a warningindication such as a flashing light or a warning sound if battery 30fails. In one aspect of the invention, any type of battery tester can beused to test such an auxiliary battery system.

The present invention can be implemented using any appropriatetechnique. One example is set forth in U.S. Pat. No. 6,172,505, issuedJan. 9, 2001, and entitled ELECTRONIC BATTERY TESTER which isincorporated herein by reference.

In one aspect, the battery test module determines battery conditionbased upon a dynamic parameter of the battery, that is a measurement ofthe battery which is made using a time varying forcing function F asshown in FIG. 4. The resultant signals in FIG. 4 can be used todetermine the dynamic parameter. Example dynamic parameters includedynamic conductance, resistance, impedance and admittance. In anotherexample, single contacts are used to obtain a measurement across thebattery.

Memory such as memory 44 within test module 16 can be used to storebattery specific information such as the rating of battery 10. Theinformation can be loaded into permanent memory during manufacture.Thus, the user is not required to enter any information regarding thebattery. This information can be used in performing the battery test andto provide a qualitative output to a user.

Output 22 can be any type of output including a visual output. Examplesinclude bi or tri-color LEDs. The color along with a flashing conditionof an LED can indicate test results such as good, bad, low charge, toolow to test, or other conditions and determinations. A flashing LED canbe used to indicate system noise, bad cell, or other conditions anddeterminations. When the user input 20 is used, the circuitry does notprovide any drain on the battery except when activated. However, aninput such a switch can increase cost and could allow a user to attempta test at an inopportune time, such as during periods of high systemnoise.

In embodiments without input 20, test module 16 can wait for a quiettime or other appropriate time to perform a test. The result can bestored in internal memory and periodically displayed on output 22/24 fora brief period. However, extended operation of the test module can drainthe battery. In one embodiment, a start-up circuit can be triggered to‘wake up’ the test module when the battery experiences a voltageincrease such as that due to charging of the battery. The circuitry canthen enter a ‘sleep’ mode based during period of non-charging in orderto save power, for example, shortly after charging stops.

The battery test module of the present invention is preferably integralwith the battery. For example, the module can be mounted to the housingsuch as to a top cover of the housing. In various embodiments, themodule can be carried within the housing or within an isolatedcompartment in the housing. The Kelvin connections can couple to thebattery terminals either through external or internal conductors.

Of course, the test circuitry and test module can be attached to thebattery through any technique including for example, techniques that donot require any modifications to the battery container. For example, itcan attach under bolts used on the battery post or can use a press fitor “trap” configuration to fit over the battery posts. This allows thecircuitry to be optionally added to existing batteries.

Further, one aspect of the invention includes any tester that isintegral with the battery or substantially permanently attached to thebattery that provides an output related to a battery condition such ascold cranking amps (CCA) and/or uses Kelvin connections to couple to thebattery.

FIG. 5 is a simplified circuit diagram of test module 16. Module 16 isshown coupled to battery 10. Module 16 operates in accordance with oneembodiment of the present invention and determines the conductance(G_(BAT)) of battery 10 and the voltage potential (V_(BAT)) betweenterminals 12 and 14. Module 16 includes current source 50, differentialamplifier 52, analog-to-digital converter 54 and microprocessor 56.Amplifier 52 is capacitively coupled to battery 10 through capacitors C₁and C₂. Amplifier 52 has an output connected to an input ofanalog-to-digital converter 54. Microprocessor 56 is connected to systemclock 58, memory 60, visual output 62 and analog-to-digital converter54. Microprocessor 56 is also capable of receiving an input from inputdevice 26. Further, an input/output (I/O) port 67 is provided.

In operation, current source 50 is controlled by microprocessor 56 andprovides a current in the direction shown by the arrow in FIG. 5. In oneembodiment, this is a square wave or a pulse. Differential amplifier 52is connected to terminals 22 and 24 of battery 10 through capacitors C₁and C₂, respectively, and provides an output related to the voltagepotential difference between terminals 12 and 14. In a preferredembodiment, amplifier 52 has a high input impedance. Circuitry 16includes differential amplifier 70 having inverting and noninvertinginputs connected to terminals 24 and 22, respectively. Amplifier 70 isconnected to measure the open circuit potential voltage (V_(BAT)) ofbattery 10 between terminals 12 and 14. The output of amplifier 70 isprovided to analog-to-digital converter 54 such that the voltage acrossterminals 12 and 14 can be measured by microprocessor 56.

Module 16 is connected to battery 10 through a four-point connectiontechnique known as a Kelvin connection. This Kelvin connection allowscurrent I to be injected into battery 10 through a first pair ofterminals while the voltage V across the terminals 12 and 14 is measuredby a second pair of connections. Because very little current flowsthrough amplifier 52, the voltage drop across the inputs to amplifier 52is substantially identical to the voltage drop across terminals 12 and14 of battery 12. The output of differential amplifier 52 is convertedto a digital format and is provided to microprocessor 56. Microprocessor56 operates at a frequency determined by system clock 58 and inaccordance with programming instructions stored in memory 60.

Microprocessor 56 determines the conductance of battery 10 by applying acurrent pulse I using current source 50. The microprocessor determinesthe change in battery voltage due to the current pulse I using amplifier52 and analog-to-digital converter 54. The value of current I generatedby current source 50 is known and is stored in memory 60. In oneembodiment, current I is obtained by applying a load to battery 10.Microprocessor 56 calculates the conductance of battery 10 using thefollowing equation:

$\begin{matrix}{{Conductance} = {G_{BAT} = \frac{\Delta\; I}{\Delta\; V}}} & {{Equation}\mspace{11mu} 1}\end{matrix}$where ΔI is the change in current flowing through battery 10 due tocurrent source 50 and ΔV is the change in battery voltage due to appliedcurrent ΔI. A temperature sensor 62 can be thermally coupled to battery10 and used to compensate battery measurements. Temperature readings canbe stored in memory 60 for later retrieval.

In one embodiment of the present invention, test module 16 includes acurrent sensor 63 which measures charge/discharge current of thebattery. The battery current measurements are utilized by microprocessor56 to relatively accurately determine state of charge and state ofhealth of battery 10.

FIG. 6 is a simple diagram for the embodiment of module 16 shown in FIG.2B. A comparator 90 can periodically compare a voltage measurement to aplurality of reference levels and responsively energize LEDs 23A–D toprovide an indication of the condition of battery 10. This display canbe provided or be activated by a switch or other condition. Any of thevarious features set forth in the Figures and discussion can be used inany appropriate combination and should not be limited to the specificexamples shown.

In one aspect of the invention, battery test module 16 is advantageouslyused while manufacturing and/or during delivery of a vehicle. Module 16can be installed in battery 10 during the vehicle manufacturing process.As the vehicle moves through the assembly line, various loads are placedon the electrical system. For example, the radio may be run, starteractuated, head lights turned on, etc. Module 16 provides an indicationif the battery has been discharged, and should be recharged (or shouldbe replaced due to failure or impending failure) prior to delivery to adealer or sale to a customer. Module 16 provides an output, such as avisual output to indicate that the battery 10 is discharged and shouldbe recharged.

The module 16 can be configured to store information based on theparticular type of rating of battery 10. This can be used in the batterytest to determine if the battery should be recharged. Module 16 can beremoved from the battery 10 once the vehicle has been assembled ordelivered. The module 16 can be reconnected and reused on anothervehicle in the assembly line.

With various aspects of the invention, including a module used duringmanufacture or delivery of a vehicle, module 16 can provide a simplepass/fail visual output, for example through colored LED(s). Additionaldata can be output to other equipment, for example, by coupling to adata bus of the vehicle, through IR, RF, an external data bus orconnection, etc. Additional information can be stored for laterretrieval such as information related to battery temperature, usage orcycle history, etc. This data can be time or date stamped and used todiagnose common failures which occur during vehicle manufacturing.Additional information can be stored in the memory such as serialnumbers, multiple battery characteristics, self learning, etc.

In general, measurements and computations carried out by module 16 canbe time or date stamped. Based on this time and date stampedinformation, module 16 can provide an output related to how long thebattery was in an unused condition when installed in a vehicle, how longthe battery was on the shelf, how long the battery was in a completelydischarged condition, etc.

FIG. 7 illustrates another embodiment of a storage battery in accordancewith the present invention. A number of items illustrated in FIG. 7 aresimilar to those shown in FIGS. 1–6 and are similarly numbered. Inaddition, FIG. 7 illustrates a remote output 92 and a remote input 94with which test module 16 can communicate via communication links 91 and93, respectively. Test module 16 can output battery conditioninformation to output 22/24 and/or to remote output device 92. Remoteoutput device 92 can be any output device such as a gauge, meter,speaker, etc. Remote output device 92 may be located, for example, in adriver cabin or on a dashboard of the vehicle in which storage battery10 is installed. Remote output device 92 may be an analog output deviceor a digital output device. Communication link 91 may be any type ofcommunication link, such as a wireless communication link, hard wiredcommunication link, optical communication link, etc. Communication link91 can also be a vehicle bus such as a Controller Area Network (CAN) busor a Local Interconnect Network (LIN) bus. Depending upon the type ofcommunication link 91 and type of remote output device 92, test module16 can provide test condition information in an appropriate form forremote output 92 to receive. Thus, test condition information can beprovided in analog form, digital form, in the form of RF signals, IRsignals, audio signals, etc. Test module 16 can also receive anactivation signal from a remote input device 94 via communication link93. Communication link 93, like above-discussed communication link 91,can be any type of communication link which can communicate anactivation signal sent from remote input 94 to test module 16. Input 94can be, for example, a remotely located push-button activation devicethat can provide the activation signal, via communication link 93, totest module 16. In some aspects, remote input 94 may provide theactivation signal automatically when a vehicle that contains storagebattery 10 is started or stopped. The activation signal may be in theform of an RF signal, an IR signal, an audio signal, digital signal, CANbus signal, LIN bus signal, etc. Remote input 94 may be located in adriver cabin of a vehicle in which battery 10 is installed, on adashboard of a vehicle in which the battery is installed, etc. Input20/26 may include a timing controller configured to apply the activationsignal after a predetermined time period. Also, remote input 94 mayinclude such a timing controller that can apply the activation signalafter a predetermined time period. Test module 16 can also providehistorical battery condition information to remote output device 92 viacommunication link 91. In some embodiments of the present invention,test module 16, communication links 91 and 93, remote output device 92and remote input 93 are part of an apparatus for testing a storagebattery.

FIG. 8 is a block diagram illustrating contents of battery conditioninformation provided to different outputs. As illustrated in FIG. 8,battery condition information 96 includes real-time measurements(battery current, voltage measurement, etc.) and computed resultsrepresented by block 97, and measurements and results stored in memory44, represented by block 98. Battery test module 16 can provide batterycondition information 96 to different outputs, such as 22, 24 and 92.

FIG. 9 illustrates a storage battery with an integrated battery testmodule in accordance with an embodiment of the present invention. Anumber of items illustrated in FIG. 9 are similar to those shown inFIGS. 1–7 and are similarly numbered. In addition, FIG. 9 shows anexternal battery charger/tester 100 with which test module 16 cancommunicate via communication link 102. One example batterycharger/tester, similar to charger/tester 100, is set forth in U.S. Pat.No. 6,104,167, issued Aug. 15, 2000, and entitled “METHOD AND APPARATUSFOR CHARGING A BATTERY” which is incorporated herein by reference.Communication link 102 may be any hard wired or wireless link, such asthose described in connection with communication links 91 and 93 (FIG.7) and can transfer battery condition information from test module 16 toexternal battery charger/tester 100. Additionally, data from externalbattery charger/tester 100 can be received by test module 16 viacommunication link 102. In some aspects, battery condition informationincludes a warranty code for storage battery 10. The warranty code canbe determined by either test module 16 or external batterycharger/tester 100. In addition, battery test module 16 can sendhistorical battery condition information from memory 44 to externalbattery charger/tester 100. As mentioned above, this historicalinformation can be utilized to monitor usage of the battery and tomaintain a record of various events in the life of the battery. Inembodiments of the present invention, battery test module 16 canimplement one or more computational algorithms which are substantiallysimilar to, and compatible with computational algorithms included inexternal battery charger/tester 100. In some aspects, the compatiblecomputational algorithms are capable of determining the state of chargeand state of health of storage battery 100. Such compatibility ofcomputational algorithms allows for an exchange of intermediatecomputations or results between the test module 16 and external batterycharger/tester 100. These exchanged intermediate computations or resultscan be utilized by test module 16 and external battery charger/tester100 to carry out additional computations.

In the embodiments of the present invention described above, the testmodule has been described as a device that can releasably attach to thebattery under bolts on the battery posts, for example, or besubstantially permanently attached to the battery. In such embodiments,the battery test module typically includes a rigid printed circuit board(PCB) with electronic components mounted on the PCB and is thereforerelatively large. Retooling of the battery case or housing is typicallyrequired to integrate such a battery test module with the batteryhousing. Further, since batteries are classified into group sizes basedon external dimensions, the addition of the relatively large batterytest module could affect the group size dimensions of the battery. Thus,although such a battery test module has several advantages over priorart battery testers, which are pieces of equipment separate from thebattery, it can be relatively costly to manufacture and install. Anembodiment of the present invention that can be affixed to a battery ofany group size without retooling the battery case or affecting the groupsize dimensions of the battery is described below in connection withFIG. 10.

FIG. 10 is a side plan view of storage battery 10 upon which batterytest module 104 is affixed. In this embodiment of the present invention,the components included in battery test module 104 function in a mannersubstantially similar to the components of battery test module 16.However, battery test module 104 is formed using flexible circuit and/orflipped chip technology and therefore test module 104 is a flexible“battery label” with embedded electronic components. Thus, test module104 can be manufactured in one size and can be affixed to a top surfacean sides of a housing of a battery of any group size. Further, sincetest module 104 is a relatively thin label, the dimensions and thereforethe group size of the battery to which it is affixed are not altered.Due to the above-mentioned advantages, battery test module 104 can beproduced at a relatively low cost and in very high volume. A techniquefor mechanically and electrically coupling test module 104 to battery 10is described below in connection with FIG. 11.

FIG. 11 is a top plan view of storage battery 10 of FIG. 10. As can beseen in FIG. 11, battery test module 104 includes components similar tothose included in test module 16 (FIG. 2A). However, as mentioned above,test module 104 is formed of multiple flexible layers. Battery testmodule 104 is coupled to battery posts 12 and 14 with the help of a“trap” configuration, pointed to by numerals 106 and 108, to fit overthe battery posts 12 and 14. Post or terminal grasping portions 106 and108 comprise grooves in battery test module 104, with electricallyconductive teeth protruding into the grooves to make electrical contactwith posts 12 and 14. Portions of battery test module 104 may besubstantially elastic to enable coupling of test module 104 to posts ofbatteries of different dimensions. A bottom surface of test module 104may be affixed to the top surface of battery 10 with the help of anysuitable adhesive. In some embodiments, a first portion of battery testmodule 104 may be affixed to the top surface of the battery housing andthe remaining portion(s) of test module 104 may be bent and affixed tosides of the housing. In some embodiments of the present invention,battery test module 104 is sufficiently thin and flexible such that itis capable of conforming to irregularities on an outer surface (top andsides) of the battery housing. In one embodiment of the presentinvention, battery test module 104 is substantially permanently affixedto the housing of battery 10. In some embodiments, battery test module104 may be temporarily affixed or selectively removable from the housingof battery 10. FIG. 12 illustrates a cross-section of a portion of anexample embodiment of test module 104. As can be seen in FIG. 12, testmodule 104 is a multi-layered structure that includes a heat spreaderlayer 110, an adhesive layer 112, a flexible substrate 114, a flexcircuit 116 and a protective layer 118. Components such as push button20, which is used to activate test module 104 to conduct a battery test,are included on a top surface of flex circuit 116, and components suchas operational amplifiers 52 and 70 and microprocessor 56 are includedon a bottom surface of flex circuit 116 and are supported by flexiblesubstrate 114 and encapsulant 124. Encapsulation of components such asamplifiers 52 and 70 and microprocessor 56 improves the robustness oftest module 104 and reduces stress on the components. Components such asamplifiers 52 and 70 and microprocessor 56 may be mounted on flexcircuit 116 using flip chip technology, surface mount technology, orother techniques as are known in the industry or are developed in thefuture. The use of flip chip technology for mounting such components isdescribed in U.S. Pat. No. 6,410,415 entitled “FLIP CHIP MOUNTINGTECHNIQUE,” which is herein incorporated by reference. Flex circuit 116is a multi-layered structure upon which some components such asresistors and push buttons (such as 20) are formed by additive orsubtractive fabrication processes and, as mentioned above, othercomponents (such as amplifiers 52 and 70 and microprocessor 56) aremounted. An example process for fabricating a flex circuit is describedin U.S. Pat. No. 6,150,071 entitled “FABRICATION PROCESS FOR FLEXCIRCUIT APPLICATIONS,” which is herein incorporated by reference.

The embodiment of test module 104 described in connection with FIG. 12is only an example embodiment of the present invention. It should benoted that a different number of layers and different types of layersmay be employed, components (such as 20, 52, 56 and 70) may bepositioned on different layers and any suitable material or combinationof materials may be employed for each layer without departing from thespirit and scope of the invention.

FIG. 13A illustrates a cross-section of a portion of battery 10 on whichbattery test module 16, 104 is mounted. As illustrated in FIG. 13A, testmodule 16, 104 couples to battery posts 12 and 14 via post extensions130 and 132. Each post extension 130, 132 is an electrically conductiveplate member having a proximal end 131 coupled to battery post 12, 14and a distal portion 133 that includes a raised member 146, 148 that isconfigured to fit into grooves such as 142 and 144 (FIG. 14) in batterytest module 16, 104. Proximal end 131 of post extension 130, 132 may beformed integral with post 12, 14, during manufacture of battery 10, ormay be annular in configuration to slidably engage with post 12, 14(FIG. 13B). The embodiment of post extension 130, 132 shown in FIG. 13Bis formed separate from post 12, 14 and can be installed on post 12, 14subsequent to battery manufacture. In the embodiment shown in FIG. 13A,post extension 130, 132 is shown as being recessed in battery housing18. However, in some embodiments, post 130, 132 may be positionedexternal to battery housing 18. In some embodiments of the presentinvention, although proximal end 131 is formed integral with distalportion 133, each of these portions may be formed from a differentconductive material. For example, proximal end 131 may be formed of aconductive metal such as copper or brass to ensure good mechanical andelectrical coupling between post 12, 14 and post extension 130, 132, anddistal portion 133 may be made of lead. Raised member 146, 148 may beformed of a metal, such as lead, which can be melted after raised member146, 148 is fit into groove 142, 144 to provide, upon cooling, securemechanical coupling between test module 16, 104 and post extension 130,132. A cover 150 may be employed to protect battery test module 16, 104and exposed portions of post extensions 130 and 132.

FIG. 14 is a top plan view of storage battery 10 showing Kelvinelectrical connections 38 and 40 between test module 16, 104 and postextensions 130 and 132. As a result of coupling test module 16, 104 tobattery post extension 130, 132 as described above, conductive pads 134and 136, 138 and 140, which are included on a bottom surface of testmodule 16, 104, are urged against post extension 130, 132 to form Kelvinconnection 38, 40.

In the embodiment of the present invention shown in FIG. 15, instead ofdistal portion 131 of post extension 130, 132 being a flat plate member,arms 130A and 130B, 132A and 132B that connect to pads 134 and 136, 138and 140 to form Kelvin connections 38, 40 are employed. In someembodiments, arms 130A and 130B, 132A and 132B may be soldered toconductive pads 134 and 136, 138 and 140. In some embodiments, postextension 130, 132 may be formed integral with test module 16, 104 andsubsequently coupled to post 12, 14. Raised members 146 and 148 are notincluded in this embodiment. Therefore, mechanical coupling betweenbattery test module 16, 104 and battery 10 is carried out usingfasteners (such as 152, 154, 156 and 158), attached to the top surfaceof battery housing 18, which are fit into grooves such as 142, 144, 160and 162 in battery test module 16, 104. Fasteners (such as 152, 154, 156and 158) may be melt caps 170 (FIG. 16-1), screw standoffs 174 (FIG.16-2) that receive screws or snap tabs 176. Melt cap 170 includes anextended portion 172 that can be melted and cooled after melt cap 170 isfit into a groove (such as 142, 144, 160 and 162) to provide securemechanical coupling between test module 16, 104 and battery 10.

The embodiments of test module 16, 104 coupled to battery 10 throughpost extensions 130 and 132 described in connection with FIGS. 113A–16are only example embodiments of the present invention. It should benoted that any suitable material or combination of materials may beemployed for proximal end 131 and distal portion 133 of post extensions130, 132. Further, proximal end 131 and distal portion 133 may be of anysuitable shape without departing from the spirit and scope of theinvention. Also, any suitable fastener may be employed to attach batterytest module 16, 104 to the housing of battery 10.

Although the present invention has been described with reference topreferred embodiments, workers skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention. Although battery 10 is described asincluding a plurality of electrochemical cells, in some embodiments ofthe present invention, battery 10 can consist of only a singleelectrochemical cell.

1. A storage battery comprising: a battery housing supporting a positivepost of the battery and a negative post of the battery; at least oneelectrochemical cell in the battery housing electrically connectedbetween to the positive post of the battery and the negative post of thebattery; a first post extension coupled to the positive post of thebattery; a second post extension coupled to the negative post of thebattery; a battery test module coupled to the first and second postextensions to form a first Kelvin connection between the battery testmodule and the first post extension and a second Kelvin connectionbetween the battery test module and the second post extension; and anoutput from the battery test module configured to output batterycondition information.
 2. The storage battery of claim 1 wherein thefirst post extension is formed integral with the positive post and thesecond post extension is formed integral with the negative post.
 3. Thestorage battery of claim 1 wherein the first post extension and thesecond post extension are formed separate from the positive and negativebattery posts, and wherein a proximal end of the first post extension isconfigured to fit onto the positive post and a proximal end of thesecond post extension is configured to fit onto the negative post. 4.The storage battery of claim 3 wherein the proximal end of the firstpost extension including a ring configured to fit onto the positivepost, and wherein the proximal end of the second post extensionincluding a ring configured to fit onto the negative post.
 5. Thestorage battery of claim 1 wherein a distal portion of the first postextension including a first raised member and a distal portion of thesecond post extension including a second raised member, and wherein eachthe first raised member and the second raised member are configured tofit into a corresponding grooves in the battery test module.
 6. Thestorage battery of claim 5 wherein the first raised member and thesecond raised member are configured to be melted and cooled to providesecure coupling between the battery test module and the first and secondpost extensions after the first raised member and the second raisedmember are fit into the corresponding grooves.
 7. The storage battery ofclaim 1 wherein the first post extension and the second post extensionare recessed in the battery housing.
 8. The storage battery of claim 1wherein the first post extension and the second post extension areexternal to the battery housing.
 9. The storage battery of claim 1wherein a proximal end of each of the first post extension and thesecond post extension comprises copper, and wherein a distal portion ofeach of the first post extension and the second post extension compriseslead.
 10. The storage battery of claim 1 wherein a proximal end of eachof the first post extension and the second post extension comprisesbrass, and wherein a distal portion of each of the first post extensionand the second post extension comprises lead.
 11. The storage battery ofclaim 1 wherein a distal portion of each of the first post extension andthe second post extension comprises a single plate member.
 12. Thestorage battery of claim 1 wherein a distal portion of each of the firstpost extension and the second post extension comprises a pair of arms.13. The storage battery of claim 1 wherein the battery test modulecomprises a first pair of contact pads that electrically couple to adistal portion of the first post extension and a second pair of contactpads that electrically couple to a distal portion of the second postextension.
 14. The storage battery of claim 1 further comprising aplurality of fasteners attached to the battery housing and extending inan upward direction from the battery housing, wherein each fastener ofthe plurality of fasteners is configured to fit into correspondinggrooves in the battery test module.
 15. The storage battery of claim 14wherein each fastener of the plurality of fasteners includes a screwstandoff configured to receive a screw.
 16. The storage battery of claim14 wherein each fastener of the plurality of fasteners is a snap tab.17. The storage battery of claim 14 wherein each fastener of theplurality of fasteners is a melt cap.
 18. The storage battery of claim17 wherein an extended portion of the melt cap is configured to bemelted and cooled to provide secure coupling between the battery housingand the battery test module when the melt cap is fit into a groove ofthe corresponding grooves.
 19. The storage battery of claim 1 whereinthe first post extension and the second post extension are formedintegral with the battery test module and configured to couple to thepositive post and the negative post.
 20. An apparatus for testing astorage battery, comprising: a first Kelvin connection coupled to afirst post extension that couples to a positive post of the battery; asecond Kelvin connection coupled to a second post extension that couplesat a negative post of the battery; a battery test module affixed to abattery housing of the storage battery and electrically coupled to thefirst and second post extensions through the respective first and secondKelvin connections; and an output from the battery test moduleconfigured to output battery condition information.
 21. The storagebattery of claim 20 wherein the first post extension and the second postextension are recessed in the battery housing.
 22. The storage batteryof claim 20 wherein the first post extension and the second postextension are formed separate from the positive and negative batteryposts, and wherein a proximal end of the first post extension isconfigured to fit onto the positive post and a proximal end of thesecond post extension is configured to fit onto the negative post. 23.An auxiliary power system, comprising: an auxiliary battery having apositive post and a negative post; a first post extension coupled to thepositive post of the auxiliary battery; a second post extension, coupledto the negative post of the auxiliary battery; a battery test moduleelectrically coupled to the auxiliary battery through the positive postextension and the negative post extension and configured to perform abattery test on the auxiliary battery and responsively provide a batterytest output; and an output configured to output results of the batterytest output.